System for producing a gypsum slurry for irrigation

ABSTRACT

In one embodiment, a method includes providing agricultural grade gypsum to a mixing device using a conveyor, providing a fluid to the mixing device using a pump, mixing the agricultural grade gypsum with the fluid to produce a gypsum slurry using the mixing device, and pumping the gypsum slurry to a storage tank. In another embodiment a system includes a conveyor providing an agricultural grade gypsum, a pump providing a fluid, a mixing device configured to mix the agricultural grade gypsum provided by the conveyor with the fluid provided by the pump to produce a gypsum slurry, and a slurry pump configured to pump the gypsum slurry from the mixing device to a storage tank.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.13/965,626 entitled “System and Method for Producing a Gypsum Slurry forIrrigation,” filed Aug. 13, 2013, which claims priority from and thebenefit of Provisional Patent Application No. 61/682,612, entitled“System for Producing a Gypsum Slurry for Irrigation,” filed Aug. 13,2012. Each of the foregoing applications is hereby incorporated byreference in its entirety.

The following applications are incorporated by reference in theirentirety:

U.S. Provisional Patent Application No. 61/682,585, entitled “System forRemoving Minerals from a Brine Using Electrodialysis” filed Aug. 13,2012,U.S. Provisional Patent Application No. 61/682,590, entitled “HeatingSystem for Desalination” filed Aug. 13, 2012,U.S. Provisional Patent Application No. 61/682,596, entitled “System forRemoving High Purity Salt from a Brine” filed Aug. 13, 2012,U.S. Provisional Patent Application No. 61/682,603, entitled “System forRinsing Electrodialysis Electrodes” filed Aug. 13, 2012, andU.S. Provisional Patent Application No. 61/682,609, entitled “System forRemoving Selenium from a Feed Stream” filed Aug. 13, 2012.

BACKGROUND

The subject matter disclosed herein relates generally to irrigation and,more particularly, to a system for preparing gypsum slurry forirrigation.

There are several regions in the United States (e.g., the southwesternUnited States including New Mexico, Southern California, and parts ofTexas) and throughout the world that experience shortages in potablewater supplies due, in part, to the arid climate of these geographiclocales. As water supplies are limited, innovative irrigation techniquesfor farm lands, parks, golf courses, and may be used.

For instance, high efficiency irrigation used in arid regions may usereclaimed water and/or treated waste water. However, using reclaimedwater and/or treated waste water may lead to soil degradation. Forexample, sodium salts and carbonates may accumulate in the soilresulting in absorption ratio toxicity in plants due to the increasedsodium to calcium ratio in the water surrounding the plant roots.Furthermore, high sodium content in plant soil may cause soil crustingwhich may inhibit irrigation water from efficiently permeating the soiland reaching plant roots. Moreover, excess carbonate soil build-up mayelevate soil pH and cause various plant nutrients to become insoluble,thus limiting the ability of plants to absorb nutrients for plantgrowth.

Gypsum may be used to improve soil quality. For example, gypsum may beused to increase the calcium content of the irrigation water and lowerthe sodium content in the soil. However, when gypsum is applied to soilas a powder, dusting issues, root absorption problems, and soil crustingmay result. In some applications, irrigation water and a gypsum slurrymay be injected directly into the soil and to the roots of plants usinga drip irrigation system. In such applications, the gypsum slurry may beadded to the drip irrigation system and applied directly to the soil ina localized manner. With the addition of the gypsum slurry to theirrigation water, application of gypsum may occur during the plantgrowing season and may perform soil conditioning without harming crops.However, scaling and plugging may occur within a drip irrigation systemsbecause of the gypsum slurry in the irrigation water.

BRIEF DESCRIPTION

In one embodiment, a method includes providing an agricultural gradegypsum to a mixing device using a conveyor, providing a fluid to themixing device using a pump, mixing the agricultural grade gypsum withthe fluid to produce a gypsum slurry using the mixing device, andpumping the gypsum slurry to a storage tank using a slurry pump.

In another embodiment, a system includes a conveyor providing anagricultural grade gypsum, a pump providing a fluid, a mixing deviceconfigured to mix the agricultural grade gypsum provided by the conveyorwith the fluid provided by the pump to produce a gypsum slurry, and aslurry pump configured to pump the gypsum slurry from the mixing deviceto a storage tank.

In another embodiment, a method includes providing a raw irrigationwater to an irrigation water pipeline at a raw irrigation waterinjection point using a raw irrigation water pump, providing an acid tothe irrigation water pipeline at an acid injection point downstream ofthe raw irrigation water injection point using an acid pump, providing agypsum slurry to the irrigation water pipeline at a gypsum slurryinjection point downstream of the acid injection point using a gypsumslurry pump, providing a bleach to the irrigation water pipeline at ableach injection point using a bleach pump to produce a raw irrigationwater mixture, and filtering the raw irrigation water mixture using afilter to produce a treated irrigation water.

DRAWINGS

These and other features, aspects, and advantages of the presentinvention will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a block diagram of an embodiment of a water processing system,in accordance with aspects of the present disclosure;

FIG. 2 is a block diagram of an embodiment of a mineral removal system,in accordance with aspects of the present disclosure;

FIG. 3 is a block diagram of another embodiment of a mineral removalsystem, in accordance with aspects of the present disclosure;

FIG. 4 is a block diagram of an embodiment of a gypsum slurry productionsystem, in accordance with aspects of the present disclosure;

FIG. 5 is a block diagram of an embodiment of an irrigation water systemusing a gypsum slurry, in accordance with aspects of the presentdisclosure; and

FIG. 6 is a block diagram of an embodiment of a gypsum slurry injectionsystem, in accordance with aspects of the present disclosure.

DETAILED DESCRIPTION

FIG. 1 is a block diagram of an embodiment of a water processing system10. The water processing system 10 is used to produce desalinated waterfrom a feed stream and to remove minerals from the feed stream. Forexample, the water processing system 10 may be used to produce highpurity agricultural grade gypsum (e.g., approximately greater than 97 wt% gypsum on a dry basis), industrial grade caustic (e.g., approximatelygreater than 97 wt % NaOH on a dry basis), industrial grade magnesiumhydroxide (e.g., approximately greater than 98 wt % MgO on an ignitedbasis, or on an ignited oxide basis) suitable for industrial magnesiarefractory, industrial grade sodium chloride (e.g., approximatelygreater than 99.9 wt % NaCl on a dry basis), and/or desalinated water(e.g., approximately less than 1000 wppm total dissolved solids (TDS))from underground brines, seawater desalination waste brines, and/orbrackish water desalination waste brines. Furthermore, the waterprocessing system 10 may use a combination of one or more of gypsumprecipitation, magnesium hydroxide precipitation, electrodialysis (ED),and/or softening and nanofiltration (NF) to remove the minerals frombrines as industrial grade products and/or to substantially reduce (oreliminate) a waste brine stream.

In the illustrated embodiment, the water processing system 10 includes apretreatment system 12 configured to receive a feed stream 14 as aninput 16. The feed stream 14 may be received from any suitable watersource. For example, the feed stream 14 may be received from groundwater, seawater, brackish water, and so forth. Moreover, the feed stream14 may contain various elements and/or compounds. For example, the feedstream 14 may contain sodium chloride (NaCl), sulfate (SO₄), calcium(Ca), magnesium (Mg), and/or silicon dioxide (silica or SiO₂). Incertain embodiments, the feed stream 14 may contain approximately 0.50to 3.00 g/l NaCl, approximately 0.10 to 1.50 g/l SO₄, approximately 0.01to 0.80 g/l Ca+Mg, and/or approximately 0.01 to 0.30 g/l SiO₂.Furthermore, in certain embodiments, the feed stream 14 may have a pHrange between approximately 5 and 9. Specifically, the feed stream 14may have a pH of approximately 8.

The pretreatment system 12 receives the feed stream 14 and removes solidmaterials (e.g., fines) from the feed stream 14. The pretreatment system12 provides the pretreated feed stream 14 as a first output 18 to areverse osmosis (RO) system 20. Moreover, the pretreatment system 12provides a second output 22 that contains fines 24, such as iron (Fe)and manganese (Mn). The RO system 20 receives the pretreated feed stream14 and produces desalinated water 28 as a first output 29. In certainembodiments, the desalinated water 28 may include SiO₂. Moreover, thedesalinated water 28 may have a pH of approximately 7.5. Furthermore,the RO system 20 provides a brine stream as a second output 30 to amineral removal system 32. In certain embodiments, the desalinated water28 may be approximately 70 to 90 percent of the output from the ROsystem 20, and the brine stream may be approximately 10 to 30 percent ofthe output from the RO system 20. Specifically, in some embodiments, thedesalinated water 28 may be approximately 80 percent of the output fromthe RO system 20, and the brine stream may be approximately 20 percentof the output from the RO system 20. As may be appreciated, while theillustrated embodiment uses the RO system 20, other embodiments may useNF in place of RO.

The mineral removal system 32 is part of a mineral removal plant 34. Themineral removal plant 34 is configured to remove minerals, elements,and/or compounds from the brine stream. As may be appreciated, the brinestream may be provided to the mineral removal plant 34 from any suitablesource and/or system. In certain embodiments, the brine stream mayinclude substantial amounts of sodium chloride, sulfate, calcium, and/ormagnesium. The mineral removal system 32 may provide one or more outputs36 that include desalinated water (which may contain silicon dioxide).Furthermore, the one or more outputs 36 may include a disinfectantand/or oxidant. The disinfectant and/or oxidant may be provided to thepretreatment system 12 via an output 38.

A lime based material 40 (e.g., lime, quick lime, dolomitic lime, etc.)may be provided to an input 42 of the mineral removal system 32 tofacilitate mineral removal from the brine stream. The mineral removalsystem 32 may be configured to remove any suitable mineral, elements,and/or compounds from the brine stream. For example, the mineral removalsystem 32 may provide a first output 44 including gypsum 46 (e.g.,agricultural grade gypsum), a second output 48 including salt 50 (e.g.,industrial grade sodium chloride), a third output 52 including magnesiumhydroxide 54 (e.g., industrial grade magnesium hydroxide), a fourthoutput 56 including bromine 58, and/or a fifth output 60 includingpotash 62.

In certain embodiments, the mineral removal system 32 may provide one ormore outputs 64 to a hydrochloric acid (HCl) and sodium hydroxide (NaOH)production system 66. Furthermore, the mineral removal system 32 mayreceive one or more inputs 68 from the HCl and NaOH production system66. For example, the mineral removal system 32 may provide a sodiumchloride brine to the HCl and NaOH production system 66. Moreover, themineral removal system 32 may receive HCl, caustic, and/or NaOH producedby the HCl and NaOH production system 66. In certain embodiments, theHCl and NaOH production system 66 may provide an output 70 of a causticsolution 72 (e.g., NaOH) or HCl solution that is not used by the mineralremoval system 32 (e.g., produced to be sold).

The mineral removal plant 34 also includes a heating and powerproduction system 74. In certain embodiments, the heating and powerproduction system 74 may include a natural gas engine and/or a boiler.The heating and power production system 74 is configured to receive afuel 76 at an input 78. The fuel 76 may be any suitable fuel, such asnatural gas. The heating and power production system 74 is configured toprovide one or more outputs 80 to the HCl and NaOH production system 66.The one or more outputs 80 may include power, steam, hot water, anysuitable heated fluid, and so forth. Moreover, the heating and powerproduction system 74 is configured to receive a cooled fluid (such aswater) via one or more inputs 82. As illustrated, the heating and powerproduction system 74 is configured to provide power to the mineralremoval system 32 via a first output 84. Moreover, the heating and powerproduction system 74 includes a second output 86 configured to providepower 88 to another system and/or to provide a power output 90 to the ROsystem 20.

FIG. 2 is a block diagram of an embodiment of the mineral removal system32. As previously described, the mineral removal system 32 receives atan input the brine stream from the output 30 of the RO system 20. As maybe appreciated, the brine stream may contain various elements and/orcompounds. For example, the brine stream may contain NaCl, SO₄, Ca, Mg,and/or SiO₂. In certain embodiments, the brine stream may containapproximately 3.0 to 8.0 g/l NaCl, approximately 3,000 to 8,000 weightparts per million (wppm) SO₄, approximately 100 to 400 wppm Mg,approximately 200 to 600 wppm Ca, and/or approximately 50 to 200 wppmSiO₂. Furthermore, in certain embodiments, the brine stream may have apH range between approximately 4 and 8. Specifically, the brine streammay have a pH of approximately 6. In the illustrated embodiment, atemperature control system 91 is used to control heating of the brinestream. Moreover, the temperature control system 91 includes a firstheat exchanger 92, a second heat exchanger 94, and a third heatexchanger 96 to aid in controlling the temperature of the brine stream.

The brine stream is mixed with HCl 98 to convert bicarbonate (CHO₃) andcarbonate (CO₃) in the brine stream to CO₂, thereby decreasing the pH toapproximately less than 4. The acidified brine stream is routed to anair stripper 100 via a first input 102. The air stripper 100 uses air104 provided to a second input 106 of the air stripper 100 to facilitateremoval of the CO₂ 108 from the brine stream via a first output 110. Incertain embodiments, multiple stages are used in the air stripper 100 toenable a low residual (e.g., less than approximately 2 ppm). As may beappreciated, a low CO₂ residual may inhibit carbonate reformation andscaling when the pH of the brine stream is increased during the variousdownstream brine treatment steps.

The CO₂ stripped brine stream is provided via a second output 111 of theair stripper 100 to a gypsum removal system 112. The gypsum removalsystem 112 may include a mixer 113, a settler 114, and a filter 115 tofacilitate removal of the gypsum 46 from the brine stream (e.g., feedstream). Accordingly, within the mixer 113, the CO₂ stripped brinestream is mixed with: the lime based material 40 (e.g., lime, quicklime, dolomitic lime, etc.) received by a first input 116 of the gypsumremoval system 112, recycled concentrated calcium chloride (CaCl₂) brine(e.g., such as a brine containing approximately 4 to 25 wt % CaCl₂)received by a second input 117, and recycled NF non-permeate (e.g., asodium sulfate (Na₂SO₄) rich brine) received by a third input 118. Incertain embodiments, such as embodiments with feed brines having a lowerNa₂SO₄ content, the second output 111 may bypass the gypsum removalsystem 112. Accordingly, only the second input 117 and the third input118 may be provided to the gypsum removal system 112. Furthermore, insuch an embodiment, the second output 111 may be mixed with a brineoutput stream 122 from the gypsum removal system 112.

HCl 98 may be added to the gypsum removal system 112 via a fourth input119. In certain embodiments, the lime based material 40 and the HCl 98may be pre-mixed into the recycle calcium chloride brine stream toincrease calcium content in the mixer 113 of the gypsum removal system112 and/or in the mineral removal system 32. For example, this may bebeneficial when the SO₄ to (Mg+Ca) molar ratio is greater thanapproximately 1.0 since it provides supplemental calcium to allowsubstantial (e.g., complete, nearly complete, etc.) sulfate removal asgypsum 46. In other embodiments, commercial calcium chloride brine,flakes, or pellets may be added to the mixer 113 of the gypsum removalsystem 112 when the brine stream is deficient in calcium. Furthermore,in certain embodiments, HCl 98 and limestone may also be added to therecycle calcium chloride brine and the brine stripped in a second airstripper to remove the residual CO₂. As may be appreciated, limestonemay be procured at a lower cost than lime; however, the second airstripper may be necessitated by the use of the limestone.

The overall molar ratio of Ca to SO₄ in the brine stream entering thegypsum removal system 112 may be controlled to approximately 0.8 to 1.2by calcium addition to the mixer 113 (e.g., HCl 98 plus the lime basedmaterial 40, CaCl₂, and/or HCl 98 plus limestone with additional airstripping) as discussed above, and/or by removing a portion of theconcentrated CaCl₂ brine as a byproduct. Recycled gypsum 46 seedcrystals are added to the mixture within the mixer 113 of the gypsumremoval system 112. The calcium in the concentrated CaCl₂ brine streamreacts with the sulfate in the brine stream received by the gypsumremoval system 112 from the air stripper 100 and the recycle NFnon-permeate to precipitate gypsum 46. In certain embodiments,approximately 50% to 70% of the sulfate is removed from the brinestream. The presence of gypsum 46 seed crystals in the mixer 113 (e.g.,a turbulent mixer) at neutral pH (e.g., a pH of approximately 6 to 8)may facilitate gypsum 46 precipitation kinetics, thereby enabling rapidgypsum precipitation. At the mixer 113 effluent the solution reachesnear saturation conditions (e.g., slightly supersaturated) with respectto gypsum 46 and the slurry is pumped to the settler 114.

In addition to gypsum 46 precipitation, insoluble calcium fluoride(CaF₂) also precipitates in the mixer 113 thereby removing a substantialportion of the fluoride from the stripped brine stream; therebyinhibiting fluoride scaling in the electrodialysis (ED) system. In thesettler 114 the gypsum 46 crystals settle and the saturated near solidsfree solution is decanted off, and filtered by the filter 115 (e.g., asand filter, a microfilter, an ultrafilter, and so forth) to removeresidual gypsum 46 particles. A small amount of softened salt brine isrecycled to the settler 114 overflow to increase gypsum 46 solubilityand desaturate the brine stream, thereby inhibiting scaling in thefilter 115 and other downstream units. The settler 114 bottoms may berouted to a hydroclone and filter to wash (e.g., with desalinatedproduct water) and concentrate the gypsum 46 into a saleable washedfilter cake. In certain embodiments, the filter cake may includeapproximately 70 to 100 wt % gypsum 46. Specifically, the filter cakemay include approximately 90 wt % gypsum 46. Thus, gypsum 46 is providedas an output 120 from the gypsum removal system 112. The fine solidsoverflow stream from the hydroclone is recycled to the mixer 113 as seedcrystals. The filtrate from the filter 115 is recycled to the settler114.

The gypsum removal system 112 may remove approximately 60 to 75% of thegypsum received from the second output 111 and produces the brine streamoutput 122 having a reduced amount of gypsum relative to the secondoutput 111. For example, the brine stream output 122 (e.g., recyclebrine stream output) may contain less than approximately 5 g/l gypsum,while the second output 111 may contain approximately 12 to 20 g/lgypsum. Furthermore, in certain embodiments, the brine stream output 122may contain approximately 5.0 to 15.0 g/l NaCl and/or approximately1,000 to 3,000 wppm SO₄. Moreover, the brine stream output 122 may havea pH of approximately 6. The brine stream output 122 is provided to anelectrodialysis (ED) system 124. Furthermore, as illustrated, the gypsumremoval system 112 is fluidly coupled to the ED system 124. In certainembodiments, a guard cartridge filter may be disposed between the brinestream output 122 and the ED system 124 to filter the brine streamoutput 122 thereby blocking gypsum scale from passing to the ED system124. The ED system 124 is configured to receive the brine stream output122 from the gypsum removal system 112, to produce a substantiallysulfate hardness (e.g., Ba, Sr, Ca) free sodium sulfate solution, toproduce a sodium chloride solution, and to produce a mineral solution.In the illustrated embodiment, the ED system 124 includes a first EDunit 126 that provides an intermediate output 128 to a second ED unit130. In certain embodiments, the intermediate output 128 may includeapproximately 70 to 120 g/l total dissolved solids (TDS).

The first ED unit 126 (e.g., mixed chloride extraction ED) extracts asubstantial portion (e.g., approximately 65% to 80%) of the magnesiumchloride, calcium chloride, and sodium chloride from the brine streamoutput 122 using non-permselective cationic membranes and monovalentpermselective anionic membranes to produce a concentrated (e.g.,approximately 3 to 25 wt %) barium chloride, strontium chloride,magnesium chloride, calcium chloride, sodium chloride brine that issubstantially sulfate free that is provided via the intermediate output128 to the second ED unit 130. At a pH of approximately 6 both boricacid and silica are in a non-ionic form and thus are not extracted bythe ED into the intermediate output 128 having the concentrated brinestream. As may be appreciated, barium (Ba), strontium (Sr), magnesium,and calcium chlorides are preferentially extracted versus sodiumchloride through non-permselective cation membranes. Thus, a diluatebrine output 160 from the first ED unit 126 is a dilute Na₂SO₄ brinewith reduced barium, strontium, calcium, and magnesium content and verylow chloride content (e.g., a substantially sulfate hardness free sodiumsulfate solution). For example, the substantially sulfate hardness freesodium sulfate solution may include less than approximately 200 mg/l(Ca+Sr+Ba) and/or approximately 3 to 5 g/l sulfate.

In certain embodiments, the first ED unit 126 may include a two-stage EDconfiguration for mixed chloride extraction ED. For example, a firststage may extract approximately 70-90% of the mixed chlorides as a lowsulfate, high concentration product concentrate. Furthermore, a secondstage may be fed by the first stage diluate and the brine stream output122. Residual mixed chlorides in the first stage diluate may beextracted into the brine stream output 122, which may be fed to thefirst stage. As may be appreciated, the two-stage design may increase EDpower consumption and size, however, the two-stage design may facilitatea sharper separation and higher recoveries of sulfate in relation to thediluate product and chloride in relation to the mixed chlorideconcentrate product.

In some embodiments, a portion of an NF non-permeate from a segregatedfully softened feed may be used as a supplemental rinse solution incells adjacent to the electrode cells, thereby inhibiting calciumcontamination of an electrode rinse solution. The return supplementalrinse solution may be recycled to the gypsum settler 114. Moreover, forseawater based brines, NF permeate may be used as a supplemental rinsesolution (due to its high salt content and higher conductivity) whichmay be recycled back to the NF feed.

The high concentration calcium chloride brine from the intermediateoutput 128 is provided to the second ED unit 130 (e.g., a NaClextraction ED) that selectively removes a substantial portion (e.g.,approximately 80% to 95%) of the NaCl using monovalent permselectivecation and anion membranes. In certain embodiments, the second ED unit130 may include a two-stage ED configuration for NaCl extraction. Forexample, a first stage may extract approximately 70 to 90% of the NaClas a low hardness, high concentration product concentrate. Moreover, thesecond stage may be fed by the first stage diluate and may produce a lowNaCl, CaCl₂, MgCl₂ rich product diluate, and an intermediateconcentration NaCl concentrate with higher hardness, which is recycledback to the feed of the first stage. As may be appreciated, thetwo-stage design may increase ED power consumption and size; however,the two-stage design may allow for a sharper separation and higherrecoveries of CaCl₂ and MgCl₂ in relation to the diluate product andNaCl in relation to the concentrate product.

A NaCl brine (e.g., sodium chloride solution) is provided as an output132 from the second ED unit 130. The NaCl brine has a low magnesiumcontent and is provided (e.g., pumped) to an ion exchange brine softener134 (e.g., such as an Amberlite™ IRC747 manufactured by The Dow ChemicalCompany of Midland, Mich.) where a substantial portion (e.g.,approximately greater than 99%) of the calcium and magnesium areremoved. Dilute HCl 98 is provided via an input 136 and NaOH 138 (e.g.,approximately 4 wt %) is provided via an input 140 to the softener 134.The HCl 98 and the NaOH 138 are used to regenerate the ion exchangebrine softener 134. The ion exchange brine softener 134 provides anoutput 142 of a high concentration NaCl brine 144. The highconcentration NaCl brine 144 may include approximately 150 to 300 g/lNaCl. In certain embodiments, the NaCl brine 144 may be provided to theHCl and NaOH production system 66 to aid in producing HCl and NaOH.Furthermore, the NaCl brine 144 may be used to regenerate a second ionexchange softener 162, such as in brackish water feed brines. Moreover,the NaCl brine 144 may be used to produce a high purity salt for a chloralkali plant, bleach plant, mixed oxidant plant, other chemical andindustrial uses, and/or for any suitable purpose. As illustrated, apurge stream may provide the NaCl brine 144 to the second ED unit 130.The pH of the purge stream may be controlled to approximately 2.5 by HCl98 injection, thereby converting residual fluoride to hydrogen fluoride(HF) and inhibiting fluorite scaling or NaCl brine contamination withfluoride. In certain embodiments, RO permeate or other low sulfate, lowsilica, low boric acid containing water may be added to prevent gypsumscaling if there is significant leakage of sulfate through themonovalent anion permselective membrane in the first ED unit 126. A lowvolume softener reject stream containing the calcium and magnesium maybe provided by an output 146 and recycled directly to the settler 114 ofthe gypsum removal system 112.

The second ED unit 130 produces a concentrated CaCl₂, MgCl₂ brine streamlow in NaCl (e.g., mineral solution) that is provided via an output 148.The output 148 is recirculated to the first ED unit 126 to aid infurther extraction of the NaCl and the production of the highconcentration NaCl brine 144. Furthermore, the output 148 is provided toa magnesium hydroxide removal system 150. As illustrated, the ED system124 is fluidly coupled to the magnesium hydroxide removal system 150. Insome embodiments (e.g., brackish water), the brine stream may containapproximately 500 to 2,000 wppm SO₄ and/or approximately 500 to 2000wppm Mg, while in other embodiments (e.g., seawater), the brine streammay contain approximately 1,500 to 4,000 wppm SO₄ and/or approximately600 to 2500 wppm Mg. Furthermore, the brine stream may have a pH ofapproximately 6. Moreover, the brine stream may include approximately 40to 60 g/l TDS. In certain embodiments, the magnesium hydroxide removalsystem 150 may include a mixer (e.g., mixer 113), a settler (e.g.,settler 114), and a filter (e.g., filter 115) to facilitate removal ofthe magnesium hydroxide from the concentrated CaCl₂, MgCl₂ brine stream(e.g., feed stream). In some embodiments, the magnesium hydroxideremoval system 150 may be configured to remove approximately 90 to 98%of Mg from the brine stream.

The low NaCl concentrated CaCl₂/MgCl₂ product brine from the ED system124 is enriched in magnesium and lean in sulfate due to the upstreamgypsum removal system 112, and the ED system 124. In certainembodiments, the brine provided to the output 148 may be approximately 1to 15% of the brine stream 30 provided to the mineral removal system 32.The lime based material 40 (e.g., lime, dolomitic lime, etc.) isprovided to the magnesium hydroxide removal system 150 via an input 152to precipitate magnesium hydroxide. A similar arrangement to the gypsumremoval system 112 (e.g., mixer 113, settler 114, filter 115, etc.) maybe used to produce a washed magnesium hydroxide filter cake and a lowmagnesium effluent brine. A portion of the magnesium hydroxide removalsystem 150 effluent may be used to produce a slaked lime slurry tofacilitate lime mixing with the CaCl₂/MgCl₂ ED product brine. Inaddition to the lime based material 40, excess NaOH 138, such as fromthe HCl and NaOH production system 66, may be provided to the magnesiumhydroxide removal system 150 via an input 154, thereby facilitating areduction in the lime based material 40 and/or reducing the CaCl₂ exportfor brines with high (Ca+Mg) to SO₄ molar feed ratios (e.g., where theratio of (Ca+Mg) to SO₄ is greater than approximately 1.0).

Overflow from a settler of the magnesium hydroxide removal system 150may provide an output 155 of concentrated CaCl₂ brine that is recycledback to the gypsum removal system 112. The CaCl₂ in the brine combineswith sulfate in the primary gypsum settler 114 to facilitateprecipitation of gypsum 46. In certain embodiments, the output 155 mayhave a pH of approximately 10. The magnesium hydroxide removal system150 outputs magnesium hydroxide slurry 156 via an output 158. In certainembodiments, the magnesium hydroxide slurry 156 may include greater thanapproximately 98 wt % magnesium oxide (MgO) on a calcinated basis.

Returning to the first ED unit 126, the first ED unit 126 provides an EDdilute stream (e.g., a substantially sulfate hardness free sodiumsulfate solution) to an output 160. Moreover, for low salinity brackishwater feeds (e.g., NaCl less than approximately 10 g/l) provided to themineral removal system 32, the ED diluate stream from the first ED unit126 has a TDS content of less than approximately 7 g/l (e.g., 5 g/l).Accordingly, as illustrated, the ED diluate stream from the first EDunit 126 is provided to a strong acid cation (SAC) ion exchange softener162. The lower TDS content of the ED diluate stream enables the use ofSAC ion exchange softening resins which are regenerated using NaCl brine144, as discussed previously. The SAC ion exchange softener 162exchanges calcium and magnesium ions in the ED diluate stream for sodiumand inhibits gypsum scaling in a downstream NF system 164 that receivesan output 166 from the SAC ion exchange softener 162. As illustrated, apurge stream of the NaCl brine 144 may be provided to the NF system 164in conjunction with the output 166 to facilitate descaling.

All or part of the ED diluate stream is routed to the SAC ion exchangesoftener 162 based a scaling potential of the NF system 164. Relativelyhigh sulfate hardness levels in the SAC softener effluent 166 (e.g.,approximately 10-100 ppm) are used to minimize brine consumption. SACion exchange softener 162 resins are regenerated using the NaCl brine144, and the spent brine from regeneration containing mainly CaCl₂ andMgCl₂ with residual NaCl is routed to the second ED unit 130, therebyfacilitating recycling of the residual NaCl for producing theconcentrated CaCl2, MgCl2 brine low in NaCl suitable for feed to themagnesium hydroxide removal system 150. As may be appreciated, forseawater based NF brines or high salinity feed brines, softening is notrequired to inhibit gypsum scaling in the downstream NF system 164. Thisis because the elevated NaCl content in the NF feed and non-permeateincreases the gypsum solubility, thereby inhibiting scaling in the NFunit.

The ED diluate stream from the first ED unit 126, which has beenoptionally softened by the SAC ion exchange softener 162 is routed tothe NF system 164 via outputs 160 and/or 166. In certain embodiments,approximately 60 to 80% of the ED diluate stream permeates the NF. Theremaining 20 to 40% NF non-permeate contains substantially all of thesulfate, approximately 60 to 90% of the calcium, approximately 80 to 90%of the magnesium, and approximately 20 to 50% of the NaCl. Thus, anon-permeate stream output from the NF system 164 via output 168 isslightly supersaturated with respect to gypsum 46 (e.g., 1.6 saturationindex defined as ion product/Ksp, which corresponds to a dissolvedgypsum content of 125% of saturation). Significant scaling does notoccur on the NF membranes of the NF system 164 because the kinetics ofgypsum crystallization are slow in the NF membranes (e.g., no seedcrystals, acidic pH, low mixing turbulence, etc.).

Periodically (e.g., approximately every 6-8 hours) a slug of high purityNaCl brine (e.g., 100-200 g/l NaCl, less than 50 ppm Ca, less than 20ppm SO4) is injected individually into each NF element of the NF system164. This may result in a brief (e.g., 30 second) period of reverse flowacross the NF membrane in a direct osmosis, high salinity process. Thehigh purity NaCl brine directs the gypsum microcrystals to be removedfrom the surface of the NF elements and dissolved in the NaCl brine,thereby inhibiting long term growth of gypsum scale since the seedmicrocrystals are removed before scaling kinetics can accelerate. Thesupersaturated NF non-permeate containing substantially all of thesulfate is recycled to the settler 114 of the gypsum removal system 112via the output 168. In certain embodiments, the supersaturated NFnon-permeate may contain approximately 8,000 to 12,000 wppm SO₄,approximately 300 to 500 wppm Ca, approximately 100 to 300 wppm Mg,approximately 0.8 to 1.5 g/l NaCl, and/or approximately 15 to 25 g/lTDS.

An NF permeate stream is provided via an output 170 from the NF system164. For low salinity brackish water brine feeds the NF permeate streammay have a low TDS and thereby may meet EPA drinking water standards.Furthermore, as may be appreciated, NF membranes with increased NaClremoval may be desirable to produce drinking water with lower TDScontent. It should be noted that the selection of the NF membrane may bemade so that silica concentration and scaling does not occur on the NFmembrane with high NaCl removal.

As illustrated, the NF permeate stream from output 170 is provided tothe HCl and NaOH production system 66. The HCl and NaOH productionsystem 66 is used to produce one or more HCl 98 outputs 172 and/or toproduce one or more NaOH 138 outputs 174. Furthermore, the NF permeatestream from output 170 may be provided to the first heat exchanger 92 tofacilitate heat transfer from the brine stream 30 to the NF permeate.Moreover, the NF permeate stream from output 170 may be provided to acooling tower 176 where the NF permeate stream is cooled before flowingthrough the third heat exchanger 96 to facilitate heat transfer from thebrine stream 30 to the NF permeate. As illustrated, the cooling tower176 may also provide a portion of the NF permeate stream to the brinestream 30.

As may be appreciated, arsenic (e.g., as arsenite) in the brine stream30 (e.g., from brackish groundwater treatment) may pass through thegypsum removal system 112 and the NF system 164, thereby ending up inthe NF permeate stream from the output 170. Accordingly, in certainembodiments, the arsenic is not removed by NF membranes. If necessary tomeet drinking water standards the arsenic may be removed from the NFpermeate stream using an arsenic absorber 178. Within the arsenicabsorber 178, the NF permeate stream is chlorinated with chlorine,sodium hypochlorite, and/or mixed oxidant 180 received via an input 182thereby converting the arsenite to arsenate. The stream is then routedto a granular ferric hydroxide (GFH) or granular ferric oxide (GFO)absorption bed where the arsenate is absorbed and chemically sequesteredas non-leachable ferric arsenate. Periodically the spent GFH or GFO maybe removed and/or stored onsite for future arsenic reclaiming. Moreover,fresh GFH or GFO may be provided into the absorption beds. The absenceof essentially all the sulfate and chloride in the NF permeate wateralong with its slightly acidic pH (e.g., approximately 5 to 6), make theGFH or GFO absorption of arsenic highly efficient and cost effective.The desalinated water 28 is provided by an output 184 from the arsenicabsorber 178. While the arsenic absorber 178 is included in theillustrated embodiment, other embodiments may not include the arsenicabsorber 178. In certain embodiments, the desalinated water 28 maycontain approximately 50 to 150 mg/l SiO₂, approximately 10 to 50 mg/lCa+Mg, approximately 0.3 to 0.9 g/l NaCl, and/or approximately 500 to1000 ppm TDS.

In certain embodiments, a slipstream of the softened ED diluate streamfrom the first ED unit 126 may be routed to a biological or chemicalselenium removal system 186. The selenium may be concentrated in thisstream because it typically exists as selenate which has similarproperties to sulfate. Moreover, the selenium does not permeate NF oranion monovalent permselective ED membranes and is more soluble thansulfate in the presence of calcium. Thus, the low NaCl, sulfate, MgCl₂and CaCl₂ concentration in the ED diluate stream provide optimalconditions for the chemical or biological removal processes. Forexample, in certain embodiments, the ED diluate stream may containapproximately 3,000 to 5,000 wppm SO₄, approximately 100 to 150 wppm Ca,approximately 25 to 75 wppm Mg, and/or approximately 0.5 to 1.0 g/lNaCl. The selenium removal system 186 is configured to remove seleniumfrom the ED diluate stream, to provide selenium 188 from a first output190, and to provide a substantially selenium free ED diluate stream tothe NF system 164.

FIG. 3 is a block diagram of another embodiment of the mineral removalsystem 32. In the illustrated embodiment, a brine stream 192 is providedto the air stripper 100 via an input 194. The brine stream 192 may bereceived from any suitable source. Furthermore, as may be appreciated,the brine stream may contain various elements and/or compounds. Forexample, the brine stream may contain NaCl, SO₄, Ca, Mg, and/or SiO₂. Incertain embodiments, the brine stream may contain approximately 25.0 to35.0 g/l NaCl, approximately 8,000 to 12,000 wppm SO₄, approximately4,000 to 6,000 wppm Mg, approximately 1,200 to 1,800 wppm Ca, and/orapproximately 1 to 5 wppm SiO₂. Furthermore, in certain embodiments, thebrine stream may have a pH range between approximately 4 and 8.Specifically, the brine stream may have a pH of approximately 6.

The air stripper 100 removes CO₂ from the brine stream 192 and providesthe stripped brine stream 192 to the gypsum removal system 112.Moreover, the gypsum removal system 112 provides the brine stream output122 to the ED system 124. The brine stream output 122 may have a pH ofapproximately 8 when it exits the gypsum removal system 112.Accordingly, HCl 98 may be added to the brine stream output 122 tofacilitate changing the pH of the brine stream output 122 to a pH ofapproximately 6. Within the ED system 124, the first ED unit 126provides the intermediate output 128 to the second ED unit 130. Incertain embodiments, the intermediate output 128 includes approximately170 to 230 g/l TDS.

The second ED unit 130 produces the concentrated CaCl₂, MgCl₂ brinestream low in NaCl (e.g., mineral solution) that is provided via theoutput 148. The output 148 is recirculated to the first ED unit 126 toaid in further extraction of the NaCl and the production of the highconcentration NaCl brine 144. Furthermore, the output 148 is provided tothe magnesium hydroxide removal system 150. In some embodiments, thebrine stream may include approximately 100 to 160 g/l TDS. Asillustrated, the ED system 124 is fluidly coupled to the magnesiumhydroxide removal system 150. Moreover, the magnesium hydroxide removalsystem 150 may be configured to remove greater than approximately 95% ofMg from the brine stream.

In certain embodiments, all or a portion of the overflow from thesettler of the magnesium hydroxide removal system 150 may be filteredand routed via an output 196 to a calcium chloride removal system 198,which may include an ED unit equipped with monovalent anionic selectivemembranes to extract a concentrated CaCl₂ brine 200 (e.g., havingapproximately 25 to 30 wt %) low in magnesium and sulfate. Furthermore,as illustrated, the magnesium hydroxide removal system 150 is fluidlycoupled to the calcium chloride removal system 198. As may beappreciated, the feed stream provided by the output 196 may have a pH ofapproximately 10 when it exits the magnesium hydroxide removal system150. Accordingly, HCl 98 may be added to the feed stream to facilitatechanging the pH of the feed stream to approximately 8. The concentratedCaCl₂ brine 200 may be provided via an output 202 and may be sold forapplications such as road dust suppression, for crude oil drillingbrine, and/or may be evaporated to produce commercial grade flakes orpellets. Moreover, the calcium chloride removal system 198 may provideCaCl₂ via an output 204 to the gypsum removal system 112. Moreover, theCaCl₂ provided via the output 204 may include approximately 80 to 100g/l CaCl₂. The calcium chloride removal system 198 may be used forseawater based brines as well as brines with high Ca+Mg to SO₄ molarfeed ratios.

The ED diluate from the first ED unit 126 is provided to the NF system164 via the output 164. In certain embodiments, the ED diluate mayinclude approximately 10 to 20 g/l TDS. Moreover, in certainembodiments, approximately 50 to 70% of the ED diluate stream permeatesthe NF. The remaining 30 to 50% NF non-permeate may be provided to thegypsum removal system 112. Furthermore, in certain embodiments, the EDdiluate from the first ED unit 126 may be recycled back to the seawaterNF used to provide the brine stream 192 thereby eliminating the need forthe NF system 164. However this may increase the size of the seawater NFunit and the NF non-permeate brine flow to the gypsum settler.

The NaCl brine 144 from the second ED unit 130 may have an increasedmagnesium content and may be pumped to the soft water regenerated ionexchange brine softener 134 (e.g., such as a Recoflo® softenermanufactured by Eco-Tec Inc. of Pickering, Ontario, Canada) in which asubstantial portion of the residual magnesium and calcium may beremoved. A fraction of the NF permeate stream from the output 170(having a low calcium and magnesium content) may be used to regeneratethe ion exchange brine softener 134. The softener reject streamcontaining the magnesium and calcium is recycled to the NF system 164where the calcium and magnesium are removed and recycled to the settler114 of the gypsum removal system 112. The NF permeate stream from theoutput 170 may also be used by the second ED unit 130. As may beappreciated, in certain embodiments, the NF permeate stream may includeapproximately 8 to 12 g/l NaCl.

For high salinity low silica feeds and seawater NF brine feeds the NFpermeate from the output 170 is routed to a reverse osmosis (RO) system206 which produces the desalinated water 28 via an output 208. Asillustrated, the desalinated water 28 may be provided to the HCl andNaOH production system 66. The RO non-permeate is routed via an output210 to a third ED unit 212 (e.g., an NaCl brine ED unit) which usesmonoselective anionic and cationic permselective membranes to produce ahigh concentration, high purity product NaCl brine 144 as a concentratestream that is provided via an output 214. The third ED unit 212 diluatecontaining the silica, sulfate, calcium and magnesium is provided via anoutput 216 and routed to a fourth ED unit 218 (e.g., a second brackishwater ED unit) which uses monoselective anionic and cationicpermselective membranes to produce desalinated water 28 via an output220 which contains the silica, sulfate, calcium, magnesium with a lowNaCl content (e.g., brackish water ED diluate). The brackish water EDdiluate received from the output 220 may be combined with the ROpermeate from the output 208 to produce a drinking water that meets theEPA TDS standard of 1000 mg/l. Moreover, the brackish water EDconcentrate brine is recycled back to the RO feed via an output 222, forrecovery of the NaCl.

FIG. 4 is a block diagram of an embodiment of a gypsum slurry productionsystem 240. In the illustrated embodiment, gypsum 46 (e.g., high purityagricultural grade gypsum with approximately greater than 97 wt % gypsumon a dry basis) from the gypsum removal system 112 may be delivered to acovered gypsum barn 242 for storage. The gypsum barn 242 may helpprotect the gypsum from the weather (e.g., rain, wind, or snow). Incertain embodiments, the gypsum 46 may be conveyed to the gypsum barn242 in the form of a filter cake using a vacuum belt filter or othertechniques. In some embodiments, the gypsum 46 (e.g., agricultural gradegypsum) may be a product of flue gas desulfurization, or the gypsum 46(e.g., agricultural grade gypsum) may be obtained by crushing minedsolution grade gypsum.

A conveyor 244 (e.g., a reclaim conveyor, a belt conveyor, a screwconveyor, a hopper, a pneumatic conveyor, a bucket conveyor, a bucketelevator, or any other suitable type of solids transport equipment) maybe used to convey the gypsum 46 from the gypsum barn 242 to a mixingdevice 246, which may be used to grind the gypsum 46, thereby reducingthe average particle size of the gypsum 46. In certain embodiments, themixing device 246 may be an attritor or a vertical ball mill and may bedriven by a mixing device motor 247. The operation of the mixing device246 is described in detail below. In the illustrated embodiment, theconveyor 244 includes a mass flow meter 248 (e.g., a belt scale or aweigh belt feeder) to measure the mass flow rate of the gypsum 46 fed tothe mixing device 246. In certain embodiments, the mass flow meter 248may be a high accuracy (e.g., less than approximately 0.25% error) beltscale with four idlers. As shown in FIG. 4, the mass flow meter 248 maygenerate an input signal 250 that is transmitted to a controller 252,which may be used to adjust one or more aspects of the gypsum slurryproduction system 240. For example, based on the information conveyed bythe input signal 250 from the mass flow meter 248, the controller 252may generate an output signal 254 that is transmitted to the conveyor244. The belt speed of the conveyor 244 may then be adjusted by thecontroller 252 to control the flow rate of gypsum 46 delivered to themixing device 246.

In certain embodiments, the controller 252 may executecomputer-implemented processes and include apparatuses for practicingthose processes. In some embodiments, the controller 252 may include acomputer program product having computer program code containinginstructions embodied in non-transitory tangible media, such as floppydiskettes, CD-ROMs, hard drives, USB (universal serial bus) drives, orany other computer-readable or machine-readable storage medium, wherein,when the computer program code is loaded into and executed by acomputer, the computer becomes an apparatus for practicing certainembodiments. In further embodiments, the controller 252 may includecomputer program code, for example, whether stored in a storage medium,loaded into and/or executed by a computer, or transmitted over sometransmission medium, such as over electrical wiring or cabling, throughfiber optics, or via wireless transmission, wherein when the computerprogram code is loaded into and executed by a computer, the computerbecomes an apparatus for practicing certain embodiments. Whenimplemented on a general-purpose processor, the computer program codesegments configure the processor to create specific logic circuits.Specifically, the controller 252 may include computer code disposed on acomputer-readable storage medium or be a process controller thatincludes such a computer-readable storage medium. The computer code mayinclude instructions for controlling, operating, and adjusting variousaspects of the gypsum slurry production system 240.

In certain embodiments, the controller 252 may be used to approximatelymatch the amount of gypsum slurry produced by the gypsum slurryproduction system 240 with an average daily gypsum slurry consumptionused for local supply. In particular, the gypsum barn 242 may be used toprovide inventory to store excess gypsum 46 when the daily gypsum slurryconsumption for local supply is less than the gypsum slurry productionrate. Similarly, the inventory of the gypsum barn 242 may be used tosupply additional gypsum 46 when the required daily slurry consumptionused for local supply is more than the gypsum slurry production rate.Thus, use of the gypsum barn 242 allows for an approximately constantrate of production of gypsum 46 by the water processing system 10 or theflue gas desulfurization plant despite a variable gypsum slurryconsumption rate, which may be characteristic of the local agriculturalmarket (e.g., a high summer demand and a low winter demand).

As shown in FIG. 4, water 256 may be delivered to the mixing device 246via a water pump 258. The flow rate of the water 256 to the mixingdevice 246 may be measured using a water flow meter 260. In certainembodiments, the water flow meter 260 may a high accuracy magnetic flowmeter (e.g., less than approximately 1% error). The controller 252 mayuse the water flow rate information provided by the water flow meter 260and the gypsum flow rate information provided by the mass flow meter 248to maintain an approximately constant water to gypsum mass flow ratio ofthe gypsum slurry, which may be between approximately 1:1 to 0.5:1.

The mixing device 246 shown in FIG. 4 combines the water 256 with thegypsum 46 to produce raw gypsum slurry 262, which may be provided to aseparation tank 264. In certain embodiments, the mixing device 246 mayinclude grinding media (e.g., stainless steel, chrome steel, tungstencarbide, ceramic, or zirconium oxide) and a plurality of cross armsrotating at a high speed and driven by motor 247 to impart both shearingand impact forces on the gypsum 46. Thus, the mixing device 246 fullywets the gypsum 46 with the water 256 and selectively grinds anyparticles of the gypsum 46 greater than a selected size to produce astable, pumpable gypsum slurry. The separation tank 264 may be used toreturn particles of gypsum 46 greater than the selected size back to themixing device 246 for further grinding. In other words, the largerparticles of gypsum 46 may tend to settle out to the bottom of theseparation tank 264 and a recirculated gypsum slurry 266 may be returnedto the mixing device 246 via a recirculation pump 268. Thus, theseparation tank 264 separates the recirculated gypsum slurry 266 from agypsum slurry 270 with all or most particles less than the selectedsize. In certain embodiments, the speed of the recirculation pump 268may be adjusted to control the recirculation flow of the recirculatedgypsum slurry 266 to the mixing device 264 to achieve a desired maximumparticle size of the gypsum slurry 270, such as a maximum particle sizeof less than approximately 0.074 mm (e.g., approximately 200 mesh).

In certain embodiments, a density meter 272 may be used to measure adensity of the gypsum slurry 270. For example, the density meter may bean online ultrasonic density meter with an accuracy within approximately0.1%. Use of the density meter 272 may allow for accurate onlinemeasurement and confirmation of the concentration of the gypsum slurry270. In other words, the density of the gypsum slurry 270 may be used toprovide an indication of the concentration (e.g., gypsum content) of thegypsum slurry 270. Further, the concentration of the gypsum slurry 270indicated by the density meter 272 may be compared with theconcentration determined using the flow rates of the gypsum 46 and thewater 256. The online density measurement may be calibrated withperiodic offline samples analyzed with a loss in weight drying scale,which directly determines gypsum solids content. The controller 252 usesthe calibrated measurements of the online density meter 272 to adjustthe ratio of water 256 to gypsum 46. Using this process may enable thesuspended solids concentration of the gypsum slurry 270 to be measuredand controlled with a less than approximately 1 wt % error of a desiredsetpoint.

In certain embodiments, a particle size meter 274 may be used to measurethe maximum particle size of the gypsum slurry 270. For example, theparticle size meter 274 may be a laser or ultrasonic online particlesize meter. The particle size meter 274 may be used to confirm that themaximum particle size of the gypsum slurry 270 is less than a desiredvalue, such as less than approximately 0.074 mm (e.g., approximately 200mesh). If the maximum particle size indicated by the particle size meter274 is greater than the desired value, the controller 252 may be used toincrease the speed of the recirculation pump 268, thereby increasing theflow rate of the recirculated gypsum slurry 266 from the separation tank264 to the mixing device 246. The increased flow rate of therecirculated gypsum slurry 266 may help reduce the maximum particle sizeof the gypsum slurry 270.

As shown in FIG. 4, the gypsum slurry 270 from the top of the separationtank 264 may be pumped by a gypsum slurry pump 276 to a storage tank278. The controller 252 may be used to control a speed of the gypsumslurry pump 276 to maintain an approximately constant fluid level in theseparation tank 264. In addition, a storage tank level meter 280 may beused to provide an indication of the level of the gypsum slurry 270 inthe storage tank 278. The level of the storage tank 278 may be used bythe controller 252 to set the flow rate of the gypsum 46 through theconveyor 244. The controller 252 may maintain an approximately constantlevel in the storage tank 278 by adjusting the flow rate of the gypsum46 without exceeding a maximum flow rate limit, which may be set by aphysical capacity limit of the mixing device 246 and/or separation tank264 or a maximum expected daily average sales volume of gypsum slurry.In addition, a gypsum slurry flow meter 282 may be disposed downstreamof the gypsum slurry pump 276 to measure a flow rate of the gypsumslurry 270. In certain embodiments, the gypsum slurry flow meter 282 maybe able to measure the flow rate of the gypsum slurry 270 with less thanapproximately 1% error. In some embodiments, a horizontal pipe 284,elbow 286, and a downward-facing discharge nozzle 288 may be installedwithin the storage tank 278 for providing the gypsum slurry 270 from thegypsum slurry pump 276. In certain embodiments, the pipe 284, elbow 286,and nozzle 288 may be ceramic lined (e.g., alumina or tungsten carbide)to inhibit erosion caused by the gypsum slurry 270. In addition, use ofthe pipe 284, elbow 286, and nozzle 288 may help increase the velocityof the gypsum slurry 270 and the nozzle 288 may direct the gypsum slurry270 downward into the slurry 270 at the top of the storage tank 278 toinhibit erosion of the interior of the storage tank 278. In someembodiments, the ceramic lined pipe 284, elbow 286, and nozzle 288 mayprovide a dynamic pressure drop (caused by flow of the gypsum slurry270) of approximately 30 to 100 kPa.

In the illustrated embodiment, a pressure gauge 290 may be disposedupstream of the pipe 284, elbow 286, and nozzle 288. In certainembodiments, the pressure gauge 290 may be a high accuracy diaphragmisolated pressure gauge. The flow rate provided by the gypsum slurryflow meter 282 and the pressure provided by the pressure gauge 290 maybe used by the controller 252 to calculate a viscosity of the gypsumslurry 270. Specifically, the gypsum slurry 270 may be a Bingham plasticfluid operated in the laminar flow regime and thus, the viscosity of thegypsum slurry 270 is proportional to the velocity and pressure dropacross the nozzle 288. The controller 252 may be used to adjust the flowrate of the recirculated gypsum slurry 266 to help maintain anapproximately constant viscosity of the gypsum slurry 270, such as anapparent viscosity of between approximately 500 to 1000 cP at a pipevelocity of between approximately 1.5 to 3 m/s. In addition, a desiredwater to gypsum mass flow ratio set point within the controller 252 maybe set sufficiently high so that both the desired viscosity and thedesired maximum particle size of the gypsum slurry 270 may be met withminimal adjustments to the flow rate of the recirculated gypsum slurry266. This may allow the flow rate of the recirculated gypsum slurry 266and the maximum particle size of the gypsum slurry to be adjusted tohelp maintain an approximately constant viscosity of the gypsum slurry270.

In certain embodiments, the storage tank 278 may be a flat bottom tankwith a length to diameter (L/D) ratio between approximately 1:1 to1:1.1. In addition, the storage tank 278 may include an agitator 292driven by a motor 294. The agitator 292 may include a slow speed (e.g.,between approximately 0.3 to 1 m/s tip speed), large diameter (e.g.,approximately 80% of tank diameter) single level impeller 293. Theimpeller 293 of the agitator 292 may be located near the bottom of thestorage tank 278 and be designed to lift the gypsum slurry 270 upwards,thereby minimizing erosion of the bottom of the storage tank 278. Incertain embodiments, the impeller 293 does not provide top to bottommixing of the gypsum slurry 270 because the storage tank 278 includes arecirculation pump 296. As shown in FIG. 4, the recirculation pump 296may be used to pump the gypsum slurry 270 from the bottom of the storagetank 278 to the top of the storage tank 278 via a recirculation line298. In some embodiments, a capacity of the storage tank 278 may beselected to allow for daytime-only deliveries of the gypsum slurry 270.For example, the capacity of the storage tank 278 may be greater thanapproximately 19,000 liters (e.g., approximately 120% of a slurry tanktruck capacity), which may allow for approximately 16 hours ofproduction. The gypsum barn 242 provides additional storage capacity asit may be more cost effective to store large volumes of gypsum 46 as adry solid in the gypsum barn 242 compared to storage of the gypsumslurry 270 in the storage tank 278.

As illustrated in FIG. 4, the recirculation pump 296 may be used toperiodically load slurry tank trucks 302 via a transfer line 300. Incertain embodiments, the capacity of a container 304 of the slurry tanktruck 302 may be between approximately 13,200 to 17,000 liters. Theslurry tank truck 302 may be equipped with internal hydraulically drivenmixers 306 to help prevent settling of the gypsum slurry 270 duringtransportation. As described below, the slurry tank truck 302 may beused to transport the gypsum slurry 270 to regional agricultural ormunicipal (e.g., reclaimed water users) gypsum slurry users. In certainembodiments, the slurry tank truck 302 include a vacuum pump/aircompressor 308, which may used to pressurize the container 304 to asuitable pressure (e.g., approximately 200 kPa) during unloading of thegypsum slurry 270.

FIG. 5 is a block diagram of an embodiment of an irrigation water system310 using the gypsum slurry 270 produced by the gypsum slurry productionsystem 240. As shown in FIG. 5, the vacuum pump/air compressor 308 maybe used to unload the gypsum slurry 270. Specifically, the slurry tanktruck 302 may include an air line 320 that enables compressed air fromthe vacuum pump/air compressor 308 to push or force the gypsum slurry270 out of the slurry tank truck 302. For example, the gypsum slurry 270from the bottom of the slurry tank truck 302 may be connected by a hose(e.g., between approximately 10 to 15 cm in diameter) to a gypsum slurrytank intake line 322, which routes the gypsum slurry 270 from the bottomof the slurry tank truck 302 to the top of a slurry receiving tank 324at the end user location.

In certain embodiments, the slurry receiving tank 324 may be a flatbottom tank with an L/D ratio between approximately 1:1 to 1.1:1 with aslow speed (e.g., between approximately 0.3 to 1 m/s tip speed) largediameter (e.g., approximately 80% of tank diameter) single levelimpeller 326 driven by a motor 328. The impeller 326 may be located nearthe bottom of the slurry receiving tank 324 and be designed to lift thegypsum slurry 270 upwards, thereby minimizing erosion of the bottom ofthe slurry receiving tank 324. In certain embodiments, the impeller 326does not provide top to bottom mixing because the gypsum slurry 270 fromthe gypsum slurry production system 240 is maintained at approximatelyconstant slurry concentration, viscosity, and maximum particle size. Insome embodiments, a capacity of the slurry receiving tank 324 may beapproximately 19,000 liters (e.g., approximately 120% of the capacity ofthe slurry tank truck 302) with dimensions of approximately 3.4 m inheight (e.g., 3 m high liquid level) and 2.9 m in diameter. Therelatively small diameter of the slurry receiving tank 324 may be usedfor the gypsum slurry 270 to help reduce the size of the impeller 326used to prevent settling of the gypsum slurry 270, without increasingthe height of the slurry receiving tank 324 to the point that a gypsumslurry booster pump would be used.

In the illustrated embodiment, a slurry chemical dosing pump 330 (e.g.,a variable speed pump) pumps the gypsum slurry 270 from the slurryreceiving tank 324 to an irrigation water pipeline 332, which may bepressurized (e.g., between approximately 200 to 345 kPa) using rawirrigation water 334 provided by a raw irrigation water pump 336. Asshown in FIG. 5, the gypsum slurry 270 may be injected into theirrigation water pipeline 332 upstream of a filter 338 used to protectthe downstream drip irrigation or sprinkler system. In certainembodiments, a low pressure shutoff switch 337 may be used toautomatically shut off the irrigation water pump 336 and all otherinjection pumps (e.g., pumps 330, 360, and 382) upon detecting a lowdischarge pressure, which may be an indication of a rupture in thedownstream irrigation system.

A gypsum slurry three-way solenoid valve 340 may be connected to theslurry receiving tank 324, purge water line 342, and a suction line ofthe slurry chemical dosing pump 330. The gypsum slurry three-waysolenoid valve 340 may provide for automatic purging of the suctionline, slurry chemical dosing pump 330, and discharge line whenever theslurry chemical dosing pump 330 is shutdown, slurry plugging issuspected, or a power outage occurs. The three-way solenoid valve 340may have non-metal wetted parts to inhibit erosion and/or corrosioncaused by the gypsum slurry 270. The three-way solenoid valve 340 may beinstalled with a normally closed port (e.g., gypsum slurry tank 324) onthe bottom, a normally open port (e.g., purge water) on the top, and acommon port (e.g., pump suction) in the middle. The purge water systemis discussed below. The bottom port (e.g., gypsum slurry tank 324) maybe rotated to allow the three-way solenoid valve 340 to be directlyconnected to the gypsum slurry tank 324. This orientation of thethree-way solenoid valve 340 may allow gypsum slurry solids in the valve340 to settle back into the tank 324 when the gypsum slurry port isclosed and may allow the purge water to periodically flow downwardthrough the valve 340, thereby flushing any settled solids into the pump330. In certain embodiments, the three-way solenoid valve 340 may be amodel SV73 three-way valve manufactured by the Valcor EngineeringCorporation of Springfield, N.J., which may have wetted parts made fromNoryl, CPVC, EPDM, or Santoprene. The SV7 three-way valve may beinstalled with the normally open port (e.g., purge water) on top, thebottom normally closed port (e.g., gypsum slurry) rotated approximately90 degrees from the normally open port (e.g., purge water), and a commonport (pump suction). Both the suction and discharge lines of the slurrychemical dosing pump 330 may be made from a relatively small diameterhigh-pressure fiber reinforced PVC tubing with a velocity betweenapproximately 0.3 to 1.2 m/s to help reduce the potential for erosionand plugging. In certain embodiments, a gypsum slurry flow meter 344 maybe used to accurately measure the flow rate of the gypsum slurry 270from the slurry chemical dosing pump 330 to confirm actual injectionrates and/or to confirm that no slurry plugging or check valvedeposition has occurred. The slurry chemical dosing pump 330 may beautomatically shutdown if the measured slurry flow does not correspondto the pump speed after an automatic purge. For example, the gypsumslurry flow meter 344 may be a magnetic flow meter. In addition, agypsum slurry level gauge 346 may be used to measure the level in theslurry receiving tank 324. In certain embodiments, the gypsum slurrylevel gauge 346 may be a non-contact ultrasonic level transmitter. Incertain embodiments, a pressurized gypsum purge drum 339 may be used toprovide purge water to the three-way solenoid valve 340. The purge drum339 may be equipped with a level transmitter 341 connected to thecontroller 391 and may also have an automatic mechanical vacuum reliefvalve 343 on the top of the drum 339, which may pull air into the drum339 as the level drops at the end of a purging cycle. A purge drum feedline 345 may be connected to the raw irrigation water line 332. Atwo-way solenoid valve 347 in the feed line 345 may be activated by thecontroller 391 to refill and repressurize the purge drum 339 upon lowlevel indicated by level transmitter 341. During a power outage, thefill line two-way solenoid valve 347 is closed (normally de-energized)and the three-way purge solenoid valve 340 isolates the gypsum slurrytank 324 and routes the pressurized purge drum 339 to the pump suction(normally de-energized position). This provides an automatic purge ofthe gypsum slurry injection pump 330 during a power outage or anirrigation water pump 336 shutdown.

As shown in FIG. 5, dilute hydrochloric acid (e.g., betweenapproximately 5 to 18 wt %) from the water processing system 10 may bedelivered by a hydrochloric acid tank truck 348 to the irrigation watersystem 310. In certain embodiments, the capacity of a container 350 ofthe hydrochloric acid tank truck 348 may be approximately 22,700 liters.In addition, the interior of the container 350 may be made from amaterial compatible with hydrochloric acid, such as high density linearpolyethylene (HDLPE). In certain embodiments, the hydrochloric acid tanktruck 348 may include a vacuum pump/air compressor 352, which may usedto pressurize the container 350 to a suitable pressure during unloadingof the hydrochloric acid. Specifically, the hydrochloric acid tank truck348 may include an air line 354 that enables compressed air from thevacuum pump/air compressor 352 to push or force the hydrochloric acidout of the hydrochloric acid tank truck 348. For example, thehydrochloric acid from the bottom of the hydrochloric acid tank truck348 may be connected by a hose to a hydrochloric acid tank intake line356, which routes the hydrochloric acid from the bottom of thehydrochloric acid tank truck 348 to the top of a hydrochloric acid tank358, which may be sized for approximately 27,200 gallons (e.g.,approximately 120% of the capacity of the hydrochloric acid tank truck348).

A hydrochloric acid dosing pump 360 (e.g., a variable speed pump) may beused to inject the dilute hydrochloric acid into the irrigation waterpipeline 332 at a distance 362 upstream of the injection point of thegypsum slurry 270. For example, the distance 362 may be greater thanapproximately 30 pipe diameters. The hydrochloric acid is used when a pHof the raw irrigation water 334 is greater than approximately 7 to helpprevent carbonate in the raw irrigation water 334 from reacting withcalcium in the dissolved gypsum of the gypsum slurry 270 and causingscaling in the downstream drip irrigation or sprinkler system. Thehydrochloric acid is injected well upstream (e.g., at least distance362) of the gypsum slurry 270 so that the hydrochloric acid is wellmixed with the raw irrigation water 334 and neutralizes the carbonatebefore the gypsum slurry 270 is injected. A hydrochloric acid two-waysolenoid valve 364 may be connected to the hydrochloric acid tank 358and the suction line of the hydrochloric acid dosing pump 360. Thetwo-way solenoid valve 364 may be de-energized (e.g., closed) when theacid dosing pump 360 is shutdown, thereby isolating the acid tank 358from the pump 360 and preventing backflow of irrigation water into theacid system. In certain embodiments, a hydrochloric acid level gauge 368may be used to measure the level in the hydrochloric acid tank 358. Incertain embodiments, the hydrochloric acid level gauge 368 may be anon-contact ultrasonic level transmitter.

In the illustrated embodiment, dilute bleach solution (e.g.,approximately 0.8 wt % sodium hypochlorite) from the water processingsystem 10 may be delivered by a bleach tank truck 370 to the irrigationwater system 310. In certain embodiments, the capacity of a container372 of the bleach tank truck 370 may be approximately 22,700 liters. Inaddition, the interior of the container 372 may be made from a materialcompatible with bleach, such as high density linear polyethylene(HDLPE). In certain embodiments, the bleach tank truck 370 may include avacuum pump/air compressor 374, which may used to pressurize thecontainer 372 to a suitable pressure during unloading of the bleach.Specifically, the bleach tank truck 370 may include an air line 376 thatenables compressed air from the vacuum pump/air compressor 374 to pushor force the bleach out of the bleach tank truck 370. For example, thebleach from the bottom of the bleach tank truck 370 may be connected bya hose to a bleach tank intake line 378, which routes the bleach fromthe bottom of the bleach tank truck 370 to the top of a bleach tank 380,which may be sized for approximately 27,200 gallons (e.g., approximately120% of the capacity of the bleach tank truck 370).

In other embodiments, concentrated (e.g., approximately 98 wt %)sulfuric acid may be used in the acid injection system instead ofhydrochloric acid. In some locations, concentrated sulfuric acid may beavailable at a lower delivered cost than the dilute hydrochloric acidproduced in the desalination plant. High temperature rated (e.g.,greater than approximately 260 degrees Celsius) PTFE tubing may be usedfor concentrated sulfuric acid because of the potential release of heatfrom concentrated sulfuric acid dilution, which may occur if irrigationwater back flows into the acid injection line.

A bleach dosing pump 382 (e.g., a variable speed pump) is used to injectthe dilute bleach solution into the irrigation water pipeline 332downstream of the injection point of the gypsum slurry 270, but upstreamof the filter 338. Injection of the bleach may help provide disinfectionfor the raw irrigation water 334 and may be important for reclaimedwater use because bleach helps prevent the formation of biologicalslimes in the filter 338 and/or the downstream drip irrigation orsprinkler system. A bleach two-way solenoid valve 384 may be connectedto the bleach tank 380 and the suction line of the bleach dosing pump382. The two-way solenoid valve 384 may be de-energized (e.g., closed)when bleach dosing pump 382 is shutdown, thereby isolating the bleachtank 380 from the pump 382 and preventing backflow of irrigation waterinto the bleach system. In certain embodiments, a bleach level gauge 388may be used to measure the level in the bleach tank 380. In certainembodiments, the bleach level gauge 388 may be a non-contact ultrasoniclevel transmitter.

In the illustrated embodiment, a filtered irrigation water flow meter390 is used to measure a flow rate of a treated irrigation water 392,which is then used by an irrigation controller 391 to adjust theinjection rates of the gypsum slurry 270, hydrochloric acid, and/orbleach, as described in detail below. The treated irrigation water 392may be analyzed using an online analyzer 394 to provide the irrigationcontroller 391 with information such as, but not limited to, calciumcomposition, pH, and free chlorine.

In certain embodiments, the irrigation controller 391 may be a remotelyaccessible building automation type programmable logic controller (PLC)and is used to control the injection rate of the gypsum slurry 270,hydrochloric acid, and/or bleach. Electronic speed (frequency) controlsmay be used to adjust speeds of the slurry chemical dosing pump 330,hydrochloric acid dosing pump 360, and/or bleach dosing pump 382 basedon the output signal 254 from the irrigation controller 391. Inaddition, the irrigation controller 391 may be used to automaticallyshutdown, isolate, and/or purge the gypsum slurry, hydrochloric acid,and bleach injection systems when the flow rate of the treatedirrigation water 392 falls below a minimum threshold for injecting thehydrochloric acid and bleach. In other respects, the irrigationcontroller 391 may be similar to the controller 252 discussed in detailabove.

In certain embodiments, the irrigation controller 391 may receive avariety of input signals 250 from the irrigation water system 310.Examples of the input signals 250 include, but are not limited to, aflow rate of the gypsum slurry (e.g., as measured by gypsum slurry flowmeter 344), a flow rate of the treated irrigation water 392 (e.g., asmeasured by filtered irrigation water flow meter 390), a minimum flowrate of the treated irrigation water 392 (e.g., as provided by a minimumflow switch), a calcium content of the treated irrigation water 392(e.g., as provided by online analyzer 394), a free chlorine content ofthe treated irrigation water 392 (e.g., as provided by online analyzer394), a pH of the treated irrigation water 392 (e.g., as provided byonline analyzer 394), a level of the gypsum slurry 270 in the slurryreceiving tank 324 (e.g., as provided by gypsum slurry level gauge 346),a level of the hydrochloric acid in the hydrochloric acid tank 358(e.g., as provided by hydrochloric acid level gauge 368), a level of thebleach in the bleach tank 380 (e.g., as provided by bleach level gauge388), minimum and maximum currents of the raw irrigation water pump 336(e.g., as provided by current switches), and/or minimum and maximumcurrents of the gypsum impeller motor 328 (e.g., as provided by currentswitches).

In addition, the irrigation controller 391 may provide a variety ofoutput signals 254 to the irrigation water system 310. Examples of theoutput signals 254 include, but are not limited to, a speed of theslurry chemical dosing pump 330, a speed of the hydrochloric acid dosingpump 360, a speed of the bleach dosing pump 382, a stop signal of theslurry chemical dosing pump 330, a stop signal of the hydrochloric aciddosing pump 360, a stop signal of the bleach dosing pump 382, a positionof the gypsum slurry three-way solenoid valve 340, a position of thehydrochloric acid three-way solenoid valve 364, and/or a position of thebleach three-way solenoid valve 384.

In certain embodiments, the irrigation controller 391 may also receiveinput signals 250 form and/or transmit output signals 254 to a remotemanagement and control interface 396. For example, the irrigationcontroller 391 may have an Ethernet connection that allows theirrigation controller 391 to connect to a wireless 3G or 4G internetrouter. Thus, the irrigation controller 391 may send and receiveinformation wirelessly 398 to a remote monitoring site over theinternet.

In certain embodiments, the irrigation controller 391 may control theflow of the gypsum slurry 270, hydrochloric acid, and/or bleach based ona flow ratio between the measured flow rate of the treated irrigationwater 392 and the flow of the gypsum slurry 270, hydrochloric acid,and/or bleach. The setpoints for each of the flow ratios may beautomatically adjusted by the irrigation controller 391 within a fixedrange based on feedback from the online analyzer 394. Thus, theirrigation controller 391 may take advantage of the redundancy ofmonitoring both injection flow ratios and treated water analysis toovercome any reliability or accuracy issues associated with the onlineanalyzer 394. In addition, the irrigation controller 391 may shutdownone or all of the injection pumps 330, 360, and 382 or purge the slurrychemical dosing pump 330 if a fault condition is detected (e.g., a lowflow rate of gypsum slurry 270 versus pump speed, a low pH, a highchlorine, a flow injection ratio vs. treated water analyzer deviation,an irrigation water flow meter and flow switch deviation, a gypsumslurry motor 328 high or low current). Further, the irrigation watersystem 310 may be remotely monitored by a central monitoring location orby an end user with a standard smartphone via the remote management andcontrol interface 396. For example, the central location and regionalplant may monitor the levels in each of the tanks 324, 358, and 380 anddispatch the tank trucks 302, 348, and 370 to maintain supplies of thegypsum slurry 270, hydrochloric acid, and bleach in the tanks 324, 358,and 380 (with end user concurrence). In some embodiments, redundantirrigation water flow meters 390 may be used so that hydrochloric acidand bleach are not injected without a minimum flow of raw irrigationwater 334. Embodiments may also include additional mechanical checkvalves, drain valves, vacuum relief valves, and/or other mechanicalvalves to comply with federal, state, and local regulations. Theseadditional valves are redundant to the automatic electronic controlsdescribed above and provide additional safeguards against irrigation,well water, and/or feed chemical contamination.

FIG. 6 is a block diagram of an embodiment of a gypsum slurry injectionsystem 408. As shown in FIG. 6, the gypsum slurry 270 may be deliveredto one or more tine injection tank trailers 410, which may include acontainer 412 that is towed through the fields before planting or duringorchard dormant phase by a tractor 414 or similar vehicle. In certainembodiments, the tine injection tank trailer 410 may include a vacuumpump/air compressor 416, which may used to pressurize the container 412to a suitable pressure (e.g., between approximately 30 to 210 kPa)during unloading of the gypsum slurry 270. Specifically, the tineinjection tank trailer 410 may include an air line 418 that enablescompressed air from the vacuum pump/air compressor 416 to push or forcethe gypsum slurry 270 out the bottom of the tine injection tank trailer410 through one or more tine injectors 420. The below grade tines of thetine injectors 420 may enable the gypsum slurry 270 to be injected belowany surface crusting and directly into the zone of maximum benefit tothe plant roots. The tine injection tank trailer 410 may be periodicallyrefilled by a hose 422 (e.g., with a diameter between approximately 10to 15 cm) through a top fill connection by slurry tank trucks 302dispatched from the gypsum slurry production system 240 of the waterprocessing system 10.

As described above, certain embodiments of the water processing system10 may include the gypsum slurry production system 240, which mayinclude the conveyor 244 for providing the gypsum 46, the water pump 258for providing the water 256, the mixing device 246 for mixing the gypsum56 with the water 256 to produce the gypsum slurry 270, and the gypsumslurry pump 276 for pumping the gypsum slurry 270 to the storage tank278. The gypsum slurry 270 may then be transported to the irrigationwater system 310 to be injected into the irrigation water pipeline 332along with hydrochloric acid and bleach produced by the water processingsystem 10. The resulting treated irrigation water 392 may then be usedfor downstream drip irrigation or sprinkler systems. Use of the gypsumslurry production system 240 may provide a number of benefits, such asproviding a low capital cost, solution grade gypsum slurry injectionsystem for lower water consumption, higher yield drip irrigationsystems. In addition, a single plant, namely the water processing system10, provides the gypsum slurry 270, bleach, and acid for the irrigationwater system 310. Any additional capital and operating costs associatedwith the gypsum slurry production system 240 is offset by a reduction inthe capacity or elimination of a solid product gypsum granulating andpackaging system. In addition, the bleach and acid production systemsare already included in the water processing system 10. Although thetransport of the gypsum slurry 270 may involve greater costs thantransporting gypsum alone, the water processing system 10 may be locatedcloser to end users than remote high purity gypsum mines. Thus regionaldistribution of the gypsum slurry 270 via the gypsum slurry productionsystem 240 may achieve a transport cost savings of greater thanapproximately 80%. Moreover, multiple gypsum slurry injection systemsmay use the common regional gypsum slurry production system 240 and selfunloading tankers 302. Each end user only has the gypsum slurry tank 324and injection pumps 330, 360, and 382, which may save approximately 50to 70% of the capital and operating cost compared to a dedicated solidsunloading and slurrying system for each end user.

In addition, the controller 252 of the gypsum slurry production system240 provides several benefits. For example, using gypsum slurry 270 withapproximately constant viscosity and concentration enables the multipleend user systems to accurately and reliably deliver gypsum to the rawirrigation water 334, by monitoring only the flow rate of the gypsumslurry 270 with a low cost slurry magnetic flow meter 344. In addition,the gypsum slurry 270 does not settle in the truck 302, tank 324, pump330, or injection tubing, rapidly dissolves in the raw irrigation water334, and does not plug the downstream filter 338 or emitters because ofthe approximately constant viscosity and maximum particle size of thegypsum slurry 270.

Further, generating the hydrochloric acid and bleach using the waterprocessing system 10 may result in reduced transportation distances forthe hydrochloric acid and bleach. This allows dilute (e.g.,approximately 5 to 18 wt % HCl) acid and bleach (e.g., approximately 0.8wt % NaOCl) to be delivered at approximately the same cost as remotelyproduced concentrated acid (e.g., approximately 98 wt % H₂SO₄) andbleach (e.g., approximately 12.5 wt %). In addition, use of relativelydilute hydrochloric acid and bleach improves handling safety, pH, andchlorination control, and may reduce or eliminate the need for hazardousprotection systems for the bleach because it is considered non-hazardousat a concentration less than approximately 0.8 wt %. Further,controlling the irrigation water system 310 to a pH betweenapproximately 6 to 6.8 enables the bleach to be over 90% effective ingenerating the required free available chlorine for disinfection. Thisallows bleach addition to be reduced by approximately 40% compared withuntreated irrigation water at a pH of 7.5, reducing both cost andenvironmental impact. It may also reduce or eliminate the possibility ofcalcium carbonate scaling due to gypsum (dissolved calcium) addition.

In addition, using the irrigation controller 391 and the remotemanagement and control interface 396 may reduce or eliminate greaterthan 90% of the staffing costs associated with conventional gypsum,acid, and bleach injection. It also may reduce operating costsapproximately 10 to 30% because a desired amount of gypsum, bleach, andacid are added. This may reduce chemical consumption, drip irrigationsystem maintenance costs, and may maintain optimal agriculturalproductivity. In addition, the gypsum slurry injection system 408 mayprovide a high efficiency, underground slurry injection system forlocations not equipped with a subsurface drip irrigation system, whichmay reduce gypsum consumption approximately 50%.

While only certain features of the invention have been illustrated anddescribed herein, many modifications and changes will occur to thoseskilled in the art. It is, therefore, to be understood that the appendedclaims are intended to cover all such modifications and changes as fallwithin the true spirit of the invention.

1. A system, comprising: a conveyor configured to receive gypsum from agypsum storage unit; a mixing device fluidly coupled to the conveyor,wherein the mixing device is configured to mix the gypsum with a fluidto produce a first gypsum slurry; a separation tank downstream from andfluidly coupled to the mixing device, wherein the separation tank isconfigured to receive the first gypsum slurry, to separate first gypsumparticles having a first particle size from second gypsum particleshaving a second particle size, greater than the first particle size, andto generate a second gypsum slurry and a third gypsum slurry, the secondgypsum slurry having the first gypsum particles and the third gypsumslurry having the second gypsum particles; a first slurry passagefluidly coupling the separation tank and a slurry storage tank, whereinthe first slurry passage is configured to supply the second gypsumslurry from the separation tank to the slurry storage tank; and a secondslurry passage fluidly coupling the mixing device and the separationtank, wherein the second slurry passage is configured to supply thethird gypsum slurry from the separation tank to the mixing device. 2.The system of claim 1, wherein the mixing device comprises an attritor,a vertical ball mill, or any combination thereof.
 3. The system of claim1, comprising a controller configured to control a viscosity, a maximumparticle size, or both, of the first gypsum slurry by adjusting a flowrate of the third gypsum slurry.
 4. The system of claim 1, comprising acontroller configured to control a concentration of the first gypsumslurry by adjusting a speed of the conveyor, a fluid flow rate of thefluid, or any combination thereof.
 5. The system of claim 1, comprisinga controller configured to increase a flow rate of the third gypsumslurry to the mixing device when the first particle size of the firstparticles within the second slurry is greater than a threshold value. 6.The system of claim 1, comprising a gypsum removal system configured toproduce the gypsum and a substantially gypsum free brine stream from alime based material, a carbon dioxide-stripped brine stream, aconcentrated calcium chloride brine, a sodium sulfate rich brine, andhydrochloric acid.
 7. The system of claim 6, wherein the gypsum removalsystem is downstream from and fluidly coupled to a reverse osmosissystem configured to produce a non-permeate stream and a desalinatedwater stream, wherein the gypsum removal system receives thenon-permeate stream from the reverse osmosis system, and thenon-permeate stream comprises the gypsum.
 8. The system of claim 1,comprising a density meter, a particle size meter, a flow meter, apressure gauge, or a combination thereof disposed along the first slurrypassage.
 9. The system of claim 1, wherein the fluid comprises water.10. A system, comprising: a reverse osmosis system configured to receivea first brine stream and to generate a second brine stream anddesalinated water, wherein the second brine stream comprises gypsum; amineral removal unit disposed downstream from and fluidly coupled to thereverse osmosis system, wherein the mineral removal unit comprises agypsum removal system configured to receive the second brine stream andto remove the gypsum from the second brine stream; and a gypsum slurryproduction system disposed downstream from the mineral removal unit,wherein the gypsum slurry production system comprises: a mixing deviceconfigured to generate a first gypsum slurry using the gypsum and afluid, wherein the first gypsum slurry comprises first gypsum particleshaving a first gypsum particle size and second gypsum particles having asecond gypsum particle size less than the first gypsum particle size; aseparation system disposed downstream from and fluidly coupled to themixing device, wherein the separation system is configured to receivethe first gypsum slurry and to produce a second gypsum slurry having thefirst gypsum particles and a third gypsum slurry having the secondgypsum particles; and a first slurry passage extending between themixing device and the separation tank, wherein the first slurry passageis configured to direct the second gypsum slurry from the separationtank to the mixing device.
 11. The system of claim 10, comprising asecond slurry passage extending between the mixing device and theseparation tank, wherein the second slurry passage is configured todirect the first gypsum slurry from the mixing device to the separationtank.
 12. The system of claim 10, comprising a conveyor disposedupstream of and fluidly coupled to the mixing device, wherein theconveyor is configured to supply the gypsum to the mixing device. 13.The system of claim 10, wherein the mixing device comprises an attritor,a vertical ball mill, or any combination thereof.
 14. The system ofclaim 10, comprising a controller configured to control a gypsum flowrate of the gypsum into the mixing device and a fluid flow rate of thefluid into the mxing device to obtain a selected ratio of the gypsum tothe fluid in the first gypsum slurry.
 15. The system of claim 10,comprising a controller configured to increase a flow rate of the secondgypsum slurry to the mixing device when the second gypsum particle sizeof the second gypsum particles of the third slurry is greater than athreshold value.
 16. The system of claim 10, comprising a slurry storagetank downstream from and fluidly coupled to the separation tank, whereinthe slurry storage tank is configured to receive the third gypsum slurryfrom the separation tank.
 17. The system of claim 16, comprising asensor disposed between the separation tank and the slurry storage tank,wherein the sensor is configured to measure a density, a particle sizeof the second gypsum particles, a pressure, a flow rate, or acombination thereof of the third gypsum slurry.
 18. A system,comprising: a gypsum slurry production system, comprising: a mixingdevice configured to mix gypsum with a fluid to produce a first gypsumslurry, wherein the first gypsum slurry comprises first gypsum particleshaving a first particle size and second gypsum particles having a secondparticle size less than the first particles size; a separation tankdisposed downstream from and fluidly coupled to the mixing device,wherein the separation tank is configured to separate the first gypsumparticles from the second gypsum particles to generate a second gypsumslurry having the first gypsum particles and a third gypsum slurryhaving the second gypsum particles; a slurry recirculation passagedisposed between the mixing device and the separation tank, wherein theslurry recirculation passage is configured to direct the third gypsumslurry to the mixing device; and a controller configured to increase aflow rate of the third gypsum slurry to the mixing device when the firstparticle size of the second gypsum particles of the second slurry isgreater than a threshold value.
 19. The system of claim 18, wherein thecontroller is configured to control a gypsum flow rate of the gypsuminto the mixing device and a fluid flow rate of the fluid into themixing device to obtain a selected ratio of the gypsum to the fluid inthe first gypsum slurry.
 20. The system of claim 19, the system of claim18 comprising a conveyor configured to provide the gypsum to the mixingdevice, wherein the controller is configured to adjust a speed of theconveyor to control the gypsum flow rate.